Alignment between charging elements of a hearing device and a charger

ABSTRACT

A method of configuring a custom insert of a charger, wherein the custom insert is for aligning a first charging element of a hearing device and a transmitter charging element of a charger, includes: obtaining a digital three-dimensional hearing device model comprising a representation of the first charging element; obtaining a digital three-dimensional charger model comprising a representation of the transmitter charging element; obtaining a digital three-dimensional insert model; obtaining a digital cavity representing a cavity in the custom insert; and creating a custom digital three-dimensional insert model based on the digital cavity and the digital three-dimensional insert model, such that the representation of the first charging element in the digital three-dimensional hearing device model and the representation of the transmitter charging element in the three-dimensional charger model, are aligned.

RELATED APPLICATION DATA

This application is a continuation of U.S. patent application Ser. No.17/411,012 filed on Aug. 24, 2021, pending, which is a continuation ofU.S. patent application Ser. No. 16/700,638 filed on Dec. 2, 2019, nowU.S. Pat. No. 11,202,157. The entire disclosure of the above applicationis expressly incorporated by reference herein.

FIELD

The present disclosure relates to a method for alignment of a receivercharging element of a hearing device and a transmitter charging elementof a charger. The present disclosure further relates to a kit comprisingthe charger comprising the transmitter charging element and the hearingdevice comprising the receiver charging element, wherein the twocharging elements are aligned.

BACKGROUND

Rechargeable hearing aids are gaining popularity because they requirelow maintenance compared to traditional hearing aids with alkalinebatteries. The rechargeable hearing aids do not generate an extra costfor a user, as there is no need for purchasing a new battery every timean old battery is drained. Furthermore, the rechargeable hearing aidshave other benefits, they are watertight, robust, environmentallyfriendly, and allow for new architectures. The rechargeable hearingdevices are typically charged wirelessly.

Wireless charging has various advantages, it is simple as a chargingdevice may simply be placed at a charging pad. Furthermore, mechanicalstrain on a charging port is reduced, as there is no plug to be pluggedand unplugged every time. Additionally, wireless charging is constantlygrowing so it will be more and more common that wireless charging padswill be installed in various places so that users can simply drop theirdevice for charging. This applies to standard devices which do notrequire special, i.e. custom, types of charging pads.

On the other hand, wireless charging is in general slower than wiredcharging as, often, a charging device and a charger may not have a goodenergy transfer due to low efficiency, and especially if the chargingdevice has a special shape, like a custom-made hearing device. Due totheir specific shape, hearing devices may require a charging station,and not a simple charging pad. Therefore, there is a need for animproved method for ensuring optimal charging of a hearing device in acharger.

SUMMARY

It is an object to provide a method for alignment between a receivercharging element and a transmitter charging element to thereby provideefficient power transfer between the two charging elements.

It is a further object to provide a method for aligning a receivercharging element with respect to the transmitter charging element, andvice versa, to thereby bring the two charging elements close to eachother in all three dimensions. When the two charging elements are closeto each other, efficient power transfer between the two chargingelements is provided.

It is yet a further object to provide a method for alignment between areceiver charging element and a transmitter charging element to therebyallow for miniaturization of a charger and a hearing device, and tofurther provide the hearing device which is more tolerant tomanufacturing inaccuracy.

It is a further object to provide a kit comprising a charger and ahearing device, where the hearing device can be easily removed from thecharger and placed in the user's ear with one movement.

It is yet a further object to provide a kit comprising a charger and ahearing device, where the hearing device can be easily removed from theuser's ear and placed in the charger with one movement

In a first aspect, a method for alignment of a receiver charging element(Rx) of a hearing device and a transmitter charging element (Tx) of acharger is provided. The hearing device is a custom rechargeable hearingdevice designed to be worn by a user. The charger comprises a custominsert, the custom insert being configured to receive the hearingdevice. The method comprises obtaining a digital scan of the user's earshape. The method further comprises creating a digital three-dimensional(3D) hearing device model based on the digital scan of the user's earshape. The position of the receiver charging element Rx is configured tobe added to the digital 3D hearing device model. Further, a digital 3Dcharger model is provided or obtained and the position of thetransmitter charging element Tx is configured to be added to the digital3D charger model. A generic digital 3D insert model is provided orobtained and a digital cavity is created in the generic digital 3Dinsert model. The digital cavity is based on the digital 3D hearingdevice model to thereby obtain a custom digital 3D insert model. Thecavity is configured to receive the hearing device. Alignment betweenthe receiver charging element Rx in the digital 3D hearing device modeland the transmitter charging element Tx in the 3D charger model isensured to thereby maximize coupling between the transmitter chargingelement Tx and receiver charging element Rx.

The method may thereby comprise obtaining the digital three-dimensionalhearing device model, wherein the digital three-dimensional hearingdevice model is based on the digital scan of an ear of the user, thedigital three-dimensional hearing device model comprising arepresentation of the receiver charging element Rx; obtaining thedigital three-dimensional charger model, the digital three-dimensionalcharger model comprising a representation of the transmitter chargingelement Tx; obtaining the generic digital three-dimensional insertmodel; obtaining the digital cavity representing the cavity in thecustom insert to be made for receiving the hearing device; and creatingthe custom digital three-dimensional insert model based on the digitalcavity and the generic digital three-dimensional insert model, whereinthe custom digital three-dimensional insert model is created such that(1) the representation of the receiver charging element Rx in thedigital three-dimensional hearing device model and (2) therepresentation of the transmitter charging element Tx in thethree-dimensional charger model, are aligned.

The custom insert may be configured to receive the hearing device sothat the hearing device only can be placed correctly in one position.The position of the receiver charging element Rx in the hearing devicewith relation to the transmitter charging element Tx in the charger isthus controlled in the use situation.

The method as described above and as specified below may be performed byan apparatus, such as a design software, a workstation, etc., and/or bya human.

The transmitter charging element Tx is comprised in the charger and havea connection point to a power supply source. The charger, i.e., thetransmitter charging element is typically driven by electric power froma power source and generates a time-varying electromagnetic field, whichtransmits power across space and towards the receiver charging elementRx in the hearing device. The power supply source may be an electriccurrent supply source, a solar power source, a light source, a handdriven dynamo or the like.

The transmitter charging element may be positioned in the bottom of thecharger. In this embodiment, the receiver charging element of thehearing device will be positioned on top of the transmitter chargingelement, once the hearing device is placed in the custom insert.Alternatively, the transmitter charging element may be positioned in thelid of the charger. In this scenario, the receiver charging element ofthe hearing device will be positioned below the transmitter chargingelement, once the hearing device is placed in the custom insert.

The receiver charging element Rx is comprised in the hearing device andis configured to extract power from the electromagnetic field producedby the transmitter charging element. The receiver charging element istypically placed in the outer part of the hearing device, i.e. the partfacing towards the user's surroundings, when the hearing device is wornby the user. The receiver charging element is typically arranged on afaceplate of the hearing device. The receiver charging element Rx iscoupled or connected to a rechargeable battery of the hearing device.The receiver charging element Rx is configured to charge therechargeable battery of the hearing device.

The transmitter charging element Tx may transfer energy wirelessly tothe receiver charging element. During the wireless energy transfer, oneof the important factors which defines efficiency of the chargingprocess is alignment between the transmitter charging element andreceiver charging element. Normally, for maximum power transfer andtherefore fast charging, the transmitter charging element and receivercharging element may be tightly coupled. Alternatively, the couplingbetween the charging elements may be loose, i.e., the receiver chargingelement may be placed anywhere in the electromagnetic field of thetransmitter charging element. In this scenario, the alignment betweenthe charging elements may be poor and only a portion of the electricflux of the transmitter charging element links to the receiver chargingelement.

Alignment between the receiver charging element and transmitter chargingelement may be obtained when the receiver charging element andtransmitter charging element are close to each other, such as as closeas physically possible to each other, such as within a predetermineddistance from each other, such as within a predetermined distance fromeach other in a z-direction, such as center-aligned in a x and/ory-direction.

Alignment between the receiver charging element and transmitter chargingelement determines coupling efficiency of a charging system comprisingthe charger and hearing device. Coupling efficiency (CE) can be computedfrom the basic efficiency formula

CE=P _(out)/(P _(out) −P _(loss))

where P_(out) is the power supplied by a power supply source andP_(loss) is the power lost during the power transfer. Maximum efficiencyof an ideal system is 100%. However, power loss occurs at variouselements of the system in addition to losses due to misalignment of thecharging elements. Optimal efficiency may be defined as efficiencyhigher than 10%, such as higher than 20%, such as higher than 25%, suchas higher than 30%. In a well-optimized charging system, the wirelesscharging can be as efficient as a wired charging. Optimal coupling isimportant because it provides fast charging and lower power consumption.

The hearing device is a custom rechargeable hearing device designed tobe worn by a user. In the present context, the term custom device isintended to mean that the device is made specifically to fit anindividual's ear canal, i.e. the ear canal of the hearing device user.Since each person's ear has a unique shape, the custom hearing devicetypically cannot be worn by another person.

The hearing device may be any custom hearing device providing sound to auser. The hearing device may include all sizes and form factors ofcustom hearing devices. The hearing device may comprise a shell and afaceplate. In the present context, the hearing device may be a hearingaid programmed/configured to compensate for a hearing loss of the userwho is a hearing-impaired person. The hearing device may have additionalfeatures, e.g. the hearing device may be configured to stream audiocontent to the user, it may be configured for user's speech extraction,etc. The hearing device may be an in-the-ear (ITE) hearing aid or be acompletely-in-the-canal (CIC) type hearing aid in which the hearingdevice is provided in the ear of the user. Typically, hearing devicecomponents, such as a processing unit, a battery, a wirelesscommunication unit, one or more microphones, etc. may be distributed onthe faceplate or in the shell. A speaker of the hearing device may bearranged in the shell or on the shell. The speaker may be arranged in/onthe end of the shell opposite to the faceplate. The speaker may pointtowards the tympanic membrane of the user, when the hearing device isarranged in its operational position in the ear of the user. The hearingdevice may comprise two hearing aids allowing for binaural hearing.These binaural hearing devices may comprise the same or differentcomponents or modules.

The rechargeable hearing device is configured to be charged by thecharger. The rechargeable hearing device may comprise a rechargeablebattery. The rechargeable battery may then power the hearing devicecomponents. The battery may be built into the hearing device. Thebattery may be arranged in the faceplate of the hearing device. Thebattery may be arranged inside the shell of the hearing device, i.e.within the volume of the hearing device shell where other components maybe arranged.

The charger is configured to charge the hearing device. The charger maycomprise a housing for securing the hearing device when the hearingdevice is charging the battery. The charger may comprise a supportstructure comprising the transmitter charging element Tx. The chargermay comprise a lid. The support structure may be the lid of the charger.The lid may comprise or be connected to the transmitter chargingelement. As an alternative the support structure may be a movable armcomprising the transmitter charging element Tx. The movable arm may beconnected to the charger housing or lid. The user may move the movablearm into a predefined position, i.e. a charging position, on top of thehearing device and thereby connecting the transmitter charging elementTx and the receiver charging element Rx. The predefined position may betemporarily locked position. The charger itself may be a rechargeabledevice configured to be charged by means of wireless or wired charging.

The charger comprises the custom insert which is configured to receivethe hearing device. The custom insert comprises at least one cavity forreceiving the hearing device. The cavity may have a mirrored geometry ofthe hearing device, i.e. the cavity may be an impression of the hearingdevice. The cavity may be configured to receive the hearing device sothat the hearing device only can be placed correctly in one position.The position of the receiver charging element Rx in the hearing devicewith relation to the transmitter charging element Tx in the charger isthus controlled in the use situation.

In this specification, the charger or any of its components, such as theinsert and the transmitter charging element, unless specifically statedotherwise, may refer to a charger or its component(s) that is alreadyproduced, or may refer to a charger or its component(s) that is to bemade, or to both. Similarly, in this specification, the hearing deviceor any of its components, such as the receiver charging element, unlessspecifically stated otherwise, may refer to a hearing device orcomponent(s) that is already produced, or may refer to a hearing deviceor component(s) that is to be made, or to both.

According to the first aspect, a digital scan of the user's ear shape isobtained. The digital scan is a digital representation of athree-dimensional (3D) image of the ear shape. The digital scancomprises data related to the shape and appearance of the ear. Thedigital scan comprises a 3D representation of at least a part of theouter ear, such as at least a part of the ear canal and the concha. Inthe present context, the digital scan may either be a digital scan of aphysical impression of the user's ear, or the digital scan can beobtained by directly scanning the ear using an ear scanner. In oneexample, a physical impression of the user's ear is made by arrangingthe impression material in the user's ear and then the physicalimpression is scanned in a 3D scanner to thereby provide the digitalscan of the user's ear. In another example, a 3D scanner may directlyscan the user's ear shape and provide the digital scan.

The user's ear shape obtained by the 3D scanning may comprise the shapeof at least a part of the user's ear canal and/or outer ear partssurrounding the ear canal, such as the concha, tragus, antitragus,and/or incisura intertragica. The digital scan may comprise informationabout at least a part of the shape of one or more of these parts of theear.

Once the digital scan is obtained, a digital 3D hearing device model iscreated based on the digital scan. The digital hearing device model is ageometrical representation of the ear surfaces and may be created by aspecialized software by importing the digital scan to thereby create thedigital 3D hearing device model of the custom hearing device. Once thedigital 3D hearing device model is created, it can be sent to a 3Dprinter for printing of the hearing device shell.

The position of the receiver charging element is configured to be addedto the digital 3D hearing device model. Typically, the receiver chargingelement is arranged in the faceplate together with other electroniccomponents of the hearing device. The position of the receiver chargingelement may be determined on the basis of miniaturization rules. Namely,a person designing the hearing device may design the faceplate andarrange the electronic components such that the device size isminimized. Alternatively, the faceplate is a pre-designed part where theelectronic components have a fixed position. The position of thereceiver charging element may partly determine the geometry of thecustom insert. When the position of the receiver charging element isadded to the digital 3D hearing device model it may form part of themodel and influence further method steps towards the alignment of thereceiver charging element and transmitter charging element.

Further, a digital 3D charger model is provided or obtained. Typically,the digital 3D charger model is a geometrical representation of thecharger and comprises physical dimensions of the charger and possiblythe lid.

The position of the transmitter charging element is configured to beadded to the digital 3D charger model. The transmitter charging elementmay be positioned in the bottom of the charger and/or in the lid of thecharger and/or a support structure connected to the charger. Theposition of the transmitter charging element may be changed during thealignment process for ensuring alignment between the transmittercharging element and the receiver charging element. The position of thetransmitter charging element in the charger may define the position ofthe cavity in the custom insert. Typically, the digital 3D charger modeland the position of the transmitter charging element are predefined andmay be provided by a third party.

A generic digital 3D insert model is then provided or obtained. Ageneric insert represented by the generic digital 3D insert model mayfit inside the charger. The generic 3D insert model may be a geometricalrepresentation of the generic insert. The generic insert may be a platehaving approximately the same dimensions as an inside cavity of thecharger housing. The generic insert may be a plate having approximatelya thickness of at least 0.5 mm, or between 1-2 mm, or between 1-1.5 mmor 1.5 mm. The generic insert may be made of a plastic material.

All the models may be provided and/or created and/or obtained using aspecialized software program. The specialised software program may beconfigured for performing digital modifications to computer aided design(CAD) files. The digitally modified CAD files may then be manufacturedby rapid prototyping, such as by computer aided manufacturing (CAM)machines, such as 3D printers etc. This may apply to all the digitalmodels in the present method.

Once the 3D hearing device model, 3D charger model, and 3D genericinsert model are provided or obtained, the digital cavity can becreated. Based on the digital cavity, a physical cavity for receivingthe hearing device may then be created in the custom insert. The digitalcavity is created in the generic digital 3D insert model. The digitalcavity is based on the digital 3D hearing device model to thereby obtaina custom digital 3D insert model. The digital cavity may be createdbased on the position of the transmitter charging element in the digital3D charger model. The position of the digital cavity in the custom 3Dinsert model may be determined by the position of the transmittercharging element in the 3D charger model and/or by the position of thereceiver charging element in the 3D hearing device model. The digitalcavity may define the volume which may be formed in the generic insertduring the manufacturing of the custom insert. Alternatively, the 3Dcustom insert model may be sent to a 3D printer for printing the custominsert comprising at least one cavity. The printed custom insert maythen be arranged in the charger.

After obtaining the custom 3D insert model, further modelling isperformed in order to ensure alignment between the receiver chargingelement in the digital 3D hearing device model and the transmittercharging element in the 3D charger model to thereby maximize couplingbetween the receiver charging element and the transmitter chargingelement. Alignment between the two charging elements can be ensured orimproved in various ways. In one embodiment, the 3D hearing device modelcan be used to optimize the position of the digital cavity in the custominsert and to thereby adjust, such as fine tune, the position of thereceiver charging element in the hearing device with respect to thetransmitter charging element in the charger. In another embodiment, theposition of the transmitter charging element in the charger is optimizedsuch that the transmitter charging element is as close as possible tothe receiver charging element in the hearing device when the hearing aidis placed in the charger and the transmitter charging element is placedin a charging position. When positioning the transmitter chargingelement, physical interference between the receiver charging element andtransmitter charging element and other physical parts of the hearingdevice and the charger is to be taken into account. Proper positioningof the charging elements also ensures that the hearing device, e.g. thefaceplate, and the charger lid or support structure do not collide andpossibly prevent proper charging and/or closing of the charger. In yetanother embodiment, both the position of the transmitter chargingelement and the position of the receiver charging element can beadjusted when aligning. The position of the receiver charging element isadjusted by optimizing the position of the digital cavity on the basisof the 3D hearing device model.

By having the custom cavity defined in the custom insert and by aligningthe charging elements in the charger and hearing device, charging speedof the hearing device may be improved compared to non-custom chargers,as the position of the receiver charging element in the hearing devicewith respect to the transmitter charging element in the charger iscontrolled. Furthermore, power consumption is decreased as theefficiency of the charging process is increased.

The method provides a guidance on how to align charging elements in thecharger and the hearing device. Adjusting the relative position of thecharging elements allows for a smaller charger compared to chargers inwhich the alignment between the charging elements was not performed.

The method according to the first aspect can be applied to a chargingsystem comprising a charger and a hearing device in which charging ofthe hearing device by the charger is performed wirelessly and wherealignment between the charger and the hearing device has an impact onthe efficiency of the charging system. For the wireless power transfer anumber of different technologies can be used such as inductive coupling,resonant inductive coupling, capacitive coupling, magneto-dynamiccoupling, microwaves, light waves, etc. The rechargeable batteries maybe lithium-ion batteries, a silver-zinc battery, etc.

The method according to the first aspect can be applied to a chargingsystem comprising a charger and a hearing device in which charging ofthe hearing device by the charger is performed by terminal or contactcharging and where alignment between the charger and the hearing devicehas an impact on the efficiency of the charging system. Terminal orcontact charging can use rechargeable batteries. For the terminal orcontact power transfer a number of different technologies and batterytypes can be used, such as alkaline batteries, galvanic charging etc.

In some embodiments, the method further comprises controlling theposition of the receiver charging element in the digital 3D hearingdevice model with respect to the position of the transmitter chargingelement. The position of the receiver charging element with respect tothe transmitter charging element may be controlled by controlling theposition of the digital cavity in x, y, and/or z direction. Bycontrolling the position of the digital cavity, the position of thereceiver charging element with respect to the transmitter chargingelement is controlled. By controlling the position of the receivercharging element relative to the transmitter charging element furtheralignment between the two is achieved and thereby the efficiency of thecharging process is increased. The positioning of the digital cavity maybe performed by the specialized software and typically before the custominsert is manufactured.

In some embodiments, the custom digital three-dimensional insert modelmay be defined by a top surface extending through a plane, wherein theposition of the receiver charging element is controlled by controllingthe position of the digital cavity along a direction parallel to theplane of the custom digital three-dimensional insert model. The planebeing an xy plane and the direction parallel to the plane correspondingto the x or y direction or a combination thereof.

The custom digital 3D insert model may be defined by a top surfaceextending through a plane and a vertical axis, the vertical axis beingperpendicular to the plane or the top surface, wherein the position ofthe receiver charging element is controlled by controlling the positionof the cavity along a direction parallel to the plane or top surface ofthe custom digital 3D insert model. According to this embodiment, aheight of a portion of the hearing device protruding from the digitalcavity above the top surface is constant, i.e. it does not change withthe digital cavity positioning. The height of a portion of the hearingdevice protruding from the digital cavity above the top surface may be3-10 mm, or 5-8 mm or 6-7 mm or 7 mm. Hereby it may be easy for the userto grab the hearing device and take it out of the charger.

By controlling the position of the digital cavity in the custom digital3D insert model, an angle between the receiver charging element andtransmitter charging element is controlled. Optimally, the receivercharging element and transmitter charging element may need to bearranged in parallel to each other. Tolerances up to ±20 degrees offsetfrom parallel may be allowed.

In some embodiments, the method may further comprise adjusting theposition of the transmitter charging element with respect to thereceiver charging element. The position of the transmitter chargingelement in the charger may be adjusted by a charger manufacturer tothereby ensure correct functionality of the charger. The manufacturermay use the digital 3D models of the hearing device and the custominsert to perform the adjustment of the transmitter charging element inthe charger to match or be aligned with the receiver charging element ofthe hearing device. Alternatively, an adjustment tool placed in thecharger may be used to thereby adjust the position of the transmittercharging element to match the position of the receiver charging elementin the hearing device. According to this embodiment, the position of thetransmitter charging element may be adjusted after the cavity forreceiving the hearing device is created. Adjusting the position of thetransmitter charging element in the charger may be performed aftermanufacturing the custom insert. Alternatively, both the position of thedigital cavity and the position of the transmitter charging element maybe adjusted. This allows for miniaturization of the charger, and designand manufacturing of custom hearing device is less challenging regardingthe tolerances. Further, adjusting the position of both the transmittercharging element and the digital cavity allows for a faster design andmanufacture of the hearing device and it prevents collisions between thetransmitter charging element in the charger and parts of the hearingdevice, e.g. a pull out wire or a volume control button at the faceplateof the hearing device. A larger custom hearing device may also beallowed if the position of the transmitter charging element in thecharger is controlled.

In some embodiments, adjusting the position of the transmitter chargingelement is performed by adjusting the position of the transmittercharging element in at least one of x or y or z directions. Thisadjustment may be performed manually with an external tool, or with theadjustment tool placed in the charger. Alternatively, the transmittercharging element may be adjusted completely manually by an operator. Thetransmitter charging element may be moved in some or all threedirections at the same time. The transmitter charging element may beembedded in a charging tower attached to the lid of the charger and thenthe charging tower may be moved in any direction thereby moving thetransmitter charging element with respect to the receiver chargingelement. This large freedom in positioning of the transmitter chargingelement in the charger allows for further improvements in chargingefficiency and power consumption. The charging tower may be a protrusionextending from an inside surface of the lid toward the position of thereceiver charging element when the hearing aid is placed in the charger.The receiver charging element may be placed in/on a surface or an endsurface of the protrusion. Wherein the surface or an end surface of theprotrusion may be close to the receiver charging element when thehearing aid is placed in the charger and the lid is closed.

In some embodiments, the method further comprises creating a digital 3Dgap in the digital cavity of the digital 3D custom insert model, thedigital 3D gap defining an air-gap between the digital cavity and thedigital 3D hearing device model. The digital 3D gap may be created bythe specialized software program by offsetting surfaces of the digitalcavity from the digital 3D hearing device model. The air-gap may mainlybe at the upper half of the digital cavity to allow for an easyinsertion/removal of the hearing device into/from the charger. The 3Dgap formed in the insert makes it easy and intuitive for the user toremove the hearing device from the charger and the custom insert andplace it in the ear with one movement and without a need forreorientation of the hearing device. Further, the defined air-gapensures that the hearing device is not too tightly inserted in thecustom insert and/or to ensure that it is not difficult to take thehearing device out from the charger and to place it back for charging.The digital 3D gap may be created by increasing a size of the digitalcavity of the custom 3D insert model. The digital 3D gap may be createdby applying transformations or modifications to the created digitalcavity. These transformations may include changing the width of thedigital cavity, carving one or more sides of the digital 3D cavitymainly in the upper half of the cavity etc. As a result of the digitalcavity transformations, the digital 3D gap is formed to make it possiblefor the user to take out the hearing device from the cavity in thecharger insert.

In some embodiments, the hearing device is an inductively chargeablehearing device. The inductively chargeable hearing device is inductivelycoupled to the charger when charging the battery of the hearing devicein the charger.

In some embodiments, the receiver charging element may be a receivercoil and the transmitter charging element may be a transmitter coil. Thereceiver coil and/or the transmitter coli may comprise at least onemagnetic coil thereby enabling inductive charging. When placed over eachother, the two coils couple inductively and can be modelled as atwo-coil transformer with an air core. The receiver charging elementcoil(s) and transmitter charging element coil(s) may have the same sizeor they may have different sizes. For an efficient power transfer, thecoils may be matched in frequency and/or in phase and be positionedclose to each other and in parallel. As distance and parallelism betweenthe coils mainly depend on the shape of the hearing device and thecustom insert, it is therefore important to design the custom insertsuch that efficiency of the energy transfer is improved.

Alternatively, the charging elements may form a galvanic contact. In yetone alternative, the charging elements may form an optical charginginterface. In yet one alternative, the charging elements may formcapacitive coupling. In this embodiment, the charging elements may be ina form of metal electrodes.

In some embodiments, the custom insert may be configured to have a firstcavity and a second cavity for receiving a first custom rechargeablehearing device and a second custom rechargeable hearing device,respectively, i.e. a first cavity for receiving the custom rechargeablehearing device, and a second cavity for receiving a second customrechargeable hearing device. Therefore, a first digital cavity and asecond digital cavity may be created in the generic 3D insert model. Thefirst and second rechargeable hearing device may differ from each otherand thereby the respective cavities may also differ from each other toaccommodate the corresponding hearing devices. The first and secondhearing device may correspond to the user's left and right hearing aid,respectively. Both of the cavities may be formed in accordance to themethod of the first aspect. The cavities may be formed simultaneously orin two separate iterations. By having two cavities in the custom insert,efficient charging of both, left and right, hearing devices is enabled.

In some embodiments, the hearing device may comprise a faceplate, andthe faceplate may comprise the receiver charging element. The faceplatemay be arranged onto/into the hearing device after a custom shell of thedevice is produced. The faceplate may be represented by a digital 3Dfaceplate model. The digital 3D faceplate model may be obtained and usedto create the digital 3D hearing device model. The digital 3D faceplatemodel may comprise the position of the receiver charging element. Anarrangement of the receiver charging element and other components on thefaceplate may be predefined or it may depend on the size of the hearingdevice. The faceplate may be a generic faceplate, where all thecomponents are in a fixed position when delivered from the manufacturerof the faceplate. The faceplate may be a custom faceplate, where thecomponents are to be placed in position in the faceplate by an operatoror designer. The faceplate may be selected from different sizes offaceplates and/or from the selection and/or quality of the components inthe faceplate. The operator assembling the hearing device may select thefaceplate for the custom shell based on the size of the shell. Anoperator or designer of the faceplate may decide the position of thereceiver charging element, depending on the shell design and in order tominiaturize the hearing device. The faceplate may comprisemicrophone(s), wireless communication unit, processor, and otherelectronics required for functioning of the hearing device and/orhearing aid. Once assembled, the arrangement of the receiver chargingelement on the faceplate may not be changed.

In some embodiments, the charger may comprise a lid. The lid may ensurethat the hearing device is securely placed inside the charger when thelid is closed. By having the charger lid, the charger together with thehearing device inside it may be transported while the charging processtakes place. The charger itself may be rechargeable. The digital 3Dcharger model may comprise a digital 3D lid model.

In some embodiments, the charger lid may comprise at least one chargingtower, the charging tower comprising the transmitter charging element.The charging tower may be movably arranged on the lid so that itsposition may be adjusted in order to match the position of the receivercharging element in the hearing device. Alternatively, the transmittercharging element may be movably arranged on/in the charging tower sothat its position may be adjusted in order to match the position of thereceiver charging element in the hearing device. Yet as an alternative,the charging towers may be stationary, without a possibility to bemoved. In this scenario, the alignment of the receiver charging elementis performed by designing the custom insert such that the two chargingelements are matched, such as within a predetermined distance from eachother. The lid of the charger may be closed in order for the charging tobe efficient. The lid of the charger may be open when placing andremoving the hearing device in the cavity of the charger insert.

In some embodiments, creating the digital cavity for receiving thehearing device in the custom digital 3D insert model may comprisedigitally removing one or more undercuts/negative draft in/from thedigital cavity. By digitally removing any undercuts or negative drafts,it is ensured that the hearing device can be placed and removed from thecavity. If any undercuts or negative drafts are not removed, the hearingdevice cannot be placed or removed from the cavity, as material in theinsert is blocking the free passage of the hearing device in the cavity.

In a second aspect, a kit includes a charger and a hearing device. Thecharger comprises a transmitter charging element and a custom insertbeing configured to receive the hearing device. The hearing device is acustom rechargeable hearing device designed to be worn by a user andcomprises a receiver charging element. The transmitter charging elementand receiver charging element are aligned using the method according toany of the embodiments according to the first aspect.

The kit according to the second aspect may utilize the method accordingto the first aspect. The skilled person would therefore readilyunderstand that any feature described in combination with the firstaspect could also be combined with the second aspect, and vice versa.Accordingly, the remarks set forth above with reference to the firstaspect are equally applicable on the second aspect.

In a third aspect, a system for alignment of a receiver charging elementof a hearing device and a transmitter charging element of a charger isprovided. The hearing device is a custom rechargeable hearing devicedesigned to be worn by a user. The charger comprises a custom insert,wherein the custom insert is configured to receive the hearing device.The system comprises one or more communication interfaces configured toobtaining a digital scan of the user's ear shape; a processing unitconfigured to creating a digital three-dimensional hearing device modelbased on the digital scan of the user's ear shape, wherein theprocessing unit is configured to add the position of the receivercharging element to the digital three-dimensional hearing device model.The one or more communication interfaces are also configured to providea digital three-dimensional charger model. The processing unit is alsoconfigured to add the position of the transmitter charging element tothe digital three-dimensional charger model. The one or morecommunication interfaces are also configured to provide a genericdigital three-dimensional insert model. The processing unit is alsoconfigured to create a digital cavity in the generic digitalthree-dimensional insert model, the digital cavity being created basedon the digital three-dimensional hearing device model to thereby obtaina custom digital three-dimensional insert model, the cavity beingconfigured to receive the hearing device. The processing unit is alsoconfigured to ensuring alignment between the receiver charging elementin the digital three-dimensional hearing device model and thetransmitter charging element in the three-dimensional charger model tothereby maximize coupling between the receiver charging element and thetransmitter charging element.

In some embodiments, the one or more communication interfaces comprisean interface for accessing a storage medium, a user interface, or acombination of the foregoing.

In a fourth aspect, a non-transitory computer-readable medium stores aset of instructions, an execution of which by a processing unit willcause a method of alignment of a receiver charging element of a hearingdevice and a transmitter charging element of a charger. The hearingdevice is a custom rechargeable hearing device designed to be worn by auser. The charger comprises a custom insert, wherein the custom insertis configured to receive the hearing device. The method comprises:

-   -   obtaining a digital scan of the user's ear shape;    -   creating a digital three-dimensional hearing device model based        on the digital scan of the user's ear shape, the position of the        receiver charging element is configured to be added to the        digital three-dimensional hearing device model;    -   providing a digital three-dimensional charger model, the        position of the transmitter charging element is configured to be        added to the digital three-dimensional charger model;    -   providing a generic digital three-dimensional insert model;    -   creating a digital cavity in the generic digital        three-dimensional insert model, the digital cavity being created        based on the digital three-dimensional hearing device model to        thereby obtain a custom digital three-dimensional insert model,        the cavity being configured to receive the hearing device; and    -   ensuring alignment between the receiver charging element in the        digital three-dimensional hearing device model and the        transmitter charging element in the three-dimensional charger        model to thereby maximize coupling between the receiver charging        element and the transmitter charging element.

The present disclosure relates to different aspects including the methoddescribed above and in the following, and a corresponding kit, a system,and a non-transitory computer-readable medium, each yielding one or moreof the benefits and advantages described in connection with the firstmentioned aspect, and each having one or more embodiments correspondingto the embodiments described in connection with the first mentionedaspect and/or disclosed in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and advantages will become readily apparentto those skilled in the art by the following detailed description ofexemplary embodiments thereof with reference to the attached drawings,in which:

FIG. 1 schematically illustrates a method for alignment of a receivercharging element of a hearing device and a transmitter charging elementof a charger,

FIG. 2 schematically illustrates a kit comprising a charger and ahearing device,

FIGS. 3 a-3 c schematically illustrate various embodiments of alignmentof a receiver charging element and a transmitter charging element,

FIG. 4 schematically illustrates creation of a digital cavity in ageneric digital 3D insert model,

FIG. 5 schematically illustrates an exemplary method for alignment ofcharging elements of a hearing device and a charger,

FIG. 6 schematically illustrates an exemplary method for alignment ofcharging elements of a hearing device and a charger.

DETAILED DESCRIPTION

Various embodiments are described hereinafter with reference to thefigures. Like reference numerals refer to like elements throughout. Likeelements will, thus, not be described in detail with respect to thedescription of each figure. It should also be noted that the figures areonly intended to facilitate the description of the embodiments. They arenot intended as an exhaustive description of the claimed invention or asa limitation on the scope of the claimed invention. In addition, anillustrated embodiment needs not have all the aspects or advantagesshown. An aspect or an advantage described in conjunction with aparticular embodiment is not necessarily limited to that embodiment andcan be practiced in any other embodiments even if not so illustrated, orif not so explicitly described.

Throughout, the same reference numerals are used for identical orcorresponding parts.

FIG. 1 schematically illustrates a method for alignment of a receivercharging element Rx of a hearing device, such as a hearing aid, and atransmitter charging element Tx of a charger. The hearing device is acustom rechargeable hearing device designed to be worn by a user. Thecharger comprises a custom insert which is configured to receive thehearing device. The method comprises at first obtaining 100 a digitalscan of the user's ear shape. The method further comprises creating 102a digital 3D hearing device model based on the digital scan of theuser's ear shape. In this step, the position of the receiver chargingelement may be added to the digital three-dimensional hearing devicemodel. The method further comprises providing or obtaining 112 a digital3D charger model. In this step, the position of the transmitter chargingelement may be added to the digital 3D charger model. The method furthercomprises providing or obtaining 104 a generic digital 3D insert modeland creating 108 a digital cavity in the generic digital 3D insertmodel. The digital cavity is created based on the digital 3D hearingdevice model to thereby obtain a custom digital 3D insert model. Thecavity is configured to receive the hearing device. Finally, the methodcomprises ensuring 114 alignment between the receiver charging elementin the digital 3D hearing device model and the transmitter chargingelement in the 3D charger model to thereby maximize coupling between thereceiver charging element and the transmitter charging element.

FIG. 2 schematically illustrates a kit comprising a charger 8 and twohearing devices 4, such as two hearing aids. The hearing devices 4comprise a receiver charging element 2 and the charger 8 comprises twotransmitter charging elements 6. The hearing devices 4 are customrechargeable hearing devices designed to be worn by a user. The charger8 comprises a custom insert 10. The custom insert 10 is configured toreceive the hearing devices 4. According to this exemplary kit, thecharger 8 comprises a lid 9. The lid 9 may comprise charging towers 11.The transmitter charging elements 6 are comprised in the charging towers11. The receiver charging elements 2 and the transmitter chargingelements 6 are aligned. Therefore, when the lid 9 is closed, the hearingdevices 4 are efficiently charged, with a charging efficiency as high as20%, such as 25%, such as 30%, and such as 35% or more.

The arrows are for indicating that the lid 9 can be moved in thedirection of the arrows for closing the charger 8 when the hearingdevices 4 should be charged.

In FIG. 2 , two hearing devices 4 are shown, and accordingly eachhearing device 4 has a receiver charging element 2. The charger 8therefore has two transmitter charging elements 6 for charging each ofthe two receiver charging elements 2, respectively.

In FIG. 2 , each hearing device 4 has a receiver charging element 2, andwhen the lid 9 of the charger 8 is closed, the transmitter chargingelements 6 are moved to a charging position where each receiver chargingelement 2 is aligned with a corresponding transmitter charging element 6in the lid 9. If the charger 8 is configured for receiving only onehearing device 4, then there may be only one transmitter chargingelement 6 in the charger 8, where the transmitter charging element 6 isconfigured to be aligned with the receiver charging element 2 of thehearing device 4, when the hearing device 4 is placed in the charger 8.

FIG. 3 schematically illustrates various embodiments of alignment of areceiver charging element 2 and a transmitter charging element 6.

FIG. 3 a schematically illustrates a charger lid 9 of a charger (notshown) with two charging towers 11, two hearing devices 4 comprising thereceiver charging elements 2, and the custom insert 10 of the charger(not shown). The custom insert 10 comprises a flat structure 13extending in a xy plane, the flat structure 13 having a top surface 13a, a bottom surface 13 b, and a peripheral rim 13 c, where cavities 12extend away from the bottom surface 13 b of the custom insert 10. Theperipheral rim 13 c of the custom insert 10 is configured to cooperatewith a rim of the charger (not shown). The rim of the charger may be aninside rim defining a cavity within the charger. Each charging tower 11comprise a transmitter charging element 6. In this embodiment, thecharging towers 11, and the transmitter charging elements 6, arestationary, i.e. their position is not adjustable, or their position isnot adjusted during the present method or process. The alignment may beachieved by controlling the position of the receiver charging element 2of the hearing device 4 which may be achieved by controlling theposition of the cavities 12 in the custom insert 10, as indicated witharrows 12 a, e.g. by moving the digital cavities 12 in the custom insert10 in a x, y and/or z direction relative to the xy plane. Positioning ofthe digital cavities 12 may be performed during the digital modellingphase and may include digitally moving the digital cavities 12 in a x, yand/or z direction relative to the xy plane, etc. A result of thedigital cavity positioning is that the position of the receiver chargingelements 2 with respect to the transmitter charging elements 6 iscontrolled and changed. Adjusting the position of the receiver chargingelements may be performed by adjusting the position of the receivercharging elements in at least one of x or y or z directions bycontrolling the position of the digital cavities 12 in the custom insert10, as indicated by the arrows 12 a (x-y-z arrows). By controlling theposition of the receiver charging elements 2 relative to the transmittercharging elements 6, alignment between the two is achieved and therebythe efficiency of the charging process is increased. The digital cavitypositioning may be performed by the specialized software program andtypically before the custom insert 10 is manufactured.

FIG. 3 b schematically illustrates a charger lid 9 with two chargingtowers 11, two hearing devices 4 comprising the receiver chargingelements 2 and the custom insert 10. The lid 9 comprises an innersurface 9 a extending in a xy plane. The xy plane may be a substantiallyflat plane or a curved plane. In this embodiment, the charging towers11, and/or the transmitter charging elements 6, may be repositioned, asindicated by arrows 6 a. Adjusting the position of the transmittercharging elements 6 may be performed by reposition of the transmittercharging elements 6 in at least one of x or y or z directions relativeto the xy plane and/or by reposition of charging towers 11 in at leastone of x or y or z directions relative to the xy plane and/or along theinner surface 9 a, as indicated by arrows 6 a (x-y-z arrows). Thisadjustment of the charging towers 11 and/or the transmitter chargingelements 6 may be performed manually with an external tool, or with anadjustment tool placed in the charger. The position of the transmittercharging elements 6 may be digitally adjusted/determined. Furthermore,the transmitter charging elements 6 may be manually adjusted to thedetermined position during the manufacturing process to obtain bettercharging efficiency. Alternatively, the transmitter charging elements 6may be adjusted completely manually by an operator. The transmittercharging elements 6 may be moved in some or all three directions at thesame time. The transmitter charging elements 6 may be moved bymoving/repositioning the charging towers 11 in any direction. This largefreedom in positioning of the transmitter charging elements 6 in thecharging towers 11 and/or the charging towers 11 in the charger lid 9allows for further improvements in charging efficiency and powerconsumption. The position of the receiver charging elements 2 of thehearing device 4 may be defined by the position of the cavity 12 in thecustom insert 10.

FIG. 3 c illustrates a combination of FIGS. 3 a and 3 b . According tothis embodiment, the alignment between the corresponding chargingelements 6, 2 is achieved by both repositioning the transmitter chargingelement 6 and/or by repositioning of the charging towers 11, asindicated by arrows 6 a, and by repositioning of the receiver chargingelements 2 by repositioning the cavity 12, as indicated by arrows 12 a.In one embodiment, a first repositioning step is made according to thedescription of FIG. 3 a and a following second repositioning step ismade according to the description of FIG. 3 b . Hereby is obtained afine tuning of the positioning of the transmitter charging elements 6and the receiver charging elements 2 relative to each other.

FIG. 4 illustrates an exemplary method for creation of a digital cavity20 in a generic digital 3D insert model 28, i.e. configuring a custominsert, as shown in FIG. 3 , to be made. The digital cavity 20 may becreated by using a specialized software program.

In order to create a digital cavity 20 in the generic digital 3D insertmodel 28, a digital scan 22 of the user's ear shape is first obtained100. The digital scan 22 comprises a 3D representation of at least apart of the outer ear, such as at least a part of the ear canal and theconcha.

Based on the digital scan 22 of the user's ear shape, a digital 3Dhearing device model 24 is created 102. The digital 3D hearing devicemodel 24 is a geometrical representation of the ear surfaces and furthera shell of the hearing device. Once the digital 3D hearing device model24 is created 102, the position of a receiver charging element is added103 to the digital 3D hearing device model 24 to thereby obtain acomplete model 26. Typically, the receiver charging element is arrangedin a faceplate together with other electronic components of the hearingdevice. The position of the receiver charging element may be determinedon the basis of miniaturization rules and geometry of the hearing deviceshell.

A generic digital 3D insert model 28 is then provided 104 or obtained.The generic digital 3D insert model 28 may comprise a flat 3D structure29 extending in a xy plane, the flat 3D structure 29 having a topsurface 29 a, a bottom surface 29 b, and a peripheral rim 29 c. Inaddition, a digital 3D charger model together with the position of atransmitter charging element is also provided or obtained (not shown).The peripheral rim 29 c of the flat 3D structure 29 may be configured tocooperate with a rim of the digital 3D charger model (not shown). Thedigital 3D hearing device model 24 or 26 which includes the position ofthe receiver charging element is then placed 105 in the generic digital3D insert model 28. The digital 3D charger model (not shown) includingthe position of the transmitter charging element (not shown) is alsoplaced 106 in the generic 3D insert model 28 to define the location ofthe digital cavity in the generic 3D insert model 28. The digital cavity20 is then created 108 in the generic 3D insert model 28. The digitalcavity 20 is created based on the complete digital 3D hearing devicemodel 26. The digital cavity 20 may extend away from the bottom surface29 b of the flat 3D structure 29. In one embodiment, the digital cavity20 may be further modified by digitally removing 109 one or moreundercuts/negative draft 30 in the digital 3D insert model 28. Bydigitally removing 109 any undercuts or negative drafts 30, it isensured that the hearing device can be placed and removed from thecavity. If any undercuts or negative drafts 30 are not removed, thehearing device cannot be placed or removed from the cavity, as materialin the insert is blocking the free passage of the hearing device in thecavity. At the end, the digital cavity 20 with well-defined cavitysurfaces is created thereby defining a digital custom insert 32.

FIG. 5 schematically illustrates an exemplary method for alignment ofcharging elements of a hearing device and a charger. According to thisembodiment, a hearing device is first designed 400. To design thehearing device, a digital scan of the user's ear shape is first obtained100. The digital scan is then imported 101 into a specialized softwareprogram and a baseline shell is created 101 based on the digital scan.The baseline shell is then further redesigned based on the digital scanto thereby create a digital 3D hearing device model. The hearing devicedesign is then complete 401 and the shell of the hearing device may bemanufactured 402 based on the hearing device design. In this embodiment,the position of the receiver charging element is defined by an operator.Namely, the operator has a complete freedom during the hearing deviceassembly to modify the shell and position a faceplate and thereby thereceiver charging element in any position to minimize the device size.

In order to design a digital cavity and a digital custom insert 403, thedigital 3D hearing device model is exported 105 into an insert layout,i.e. into a generic digital 3D insert model. The generic digital 3Dinsert model is transformed 404 to create a digital cavity and thelocation of the cavity is defined 405. The transformation is performedbased on the digital 3D hearing device model and the location of thedigital cavity may be based on the position of a representation of thetransmitter charging element in the digital 3D charger model.

Once the custom insert is manufactured, it can be installed into thecharger, 408. The hearing device to be charged may also be inserted intothe custom insert. According to this embodiment, the position of thetransmitter charging element can be adjusted 409 and the chargingfunction may be confirmed. According to this embodiment, alignmentbetween the receiver charging element and the transmitter chargingelement is obtained by adjusting the position of the transmittercharging element. The hearing device and the charger are then complete410 and ready for shipment.

This embodiment allows for maximum miniaturization of the hearing deviceand the charger.

FIG. 6 schematically illustrates an exemplary method for alignment ofcharging elements of a hearing device and a charger. The differencebetween this embodiment and the embodiment illustrated in FIG. 5 is inthat the position of the receiver charging element is defined 501 duringthe device design process 500 and that the digital 3D hearing devicemodel is exported 105 into an insert layout, i.e. into a generic digital3D insert model with/comprising a representation of the position of thereceiver charging element defined in 501. Furthermore, a final step inthe digital cavity creation is; defining the digital cavity alignment406 which tunes the position of the representation of the receivercharging element and the representation of the transmitter chargingelement to thereby align the two charging elements in the hearing deviceand the charger. After this step, the custom insert may be manufactured407. Furthermore, according to this embodiment, step 409 is optional,i.e. the position of the transmitter charging element may be adjusted409 and the charging function may be confirmed. Alternatively, only thecharging function may be confirmed. According to this embodiment, theoperator assembling the hearing device has almost no freedom to modifythe shell and the faceplate in order to minimize the hearing device.Thus, according to the method of FIG. 6 , the alignment between thetransmitter charging element and the receiver charging element may beobtained by digital modelling of the position of the hearing device inthe insert and/or by positioning of the transmitter charging element inthe charger.

Although particular features have been shown and described, it will beunderstood that they are not intended to limit the claimed invention,and it will be made obvious to those skilled in the art that variouschanges and modifications may be made without departing from the scopeof the claimed invention. The specification and drawings are,accordingly to be regarded in an illustrative rather than restrictivesense. The claimed invention is intended to cover all alternatives,modifications and equivalents.

The embodiments may be provided according to any one or any combinationof the following items:

1. A method for alignment of a receiver charging element of a hearingdevice and a transmitter charging element of a charger, the hearingdevice being a custom rechargeable hearing device designed to be worn bya user, the charger comprising a custom insert, the custom insert beingconfigured to receive the hearing device,

the method comprising:

-   -   obtaining a digital scan of the user's ear shape;    -   creating a digital three-dimensional hearing device model based        on the digital scan of the user's ear shape, the position of the        receiver charging element is configured to be added to the        digital three-dimensional hearing device model;    -   providing a digital three-dimensional charger model, the        position of the transmitter charging element is configured to be        added to the digital three-dimensional charger model;    -   providing a generic digital three-dimensional insert model;    -   creating a digital cavity in the generic digital        three-dimensional insert model, the digital cavity being created        based on the digital three-dimensional hearing device model to        thereby obtain a custom digital three-dimensional insert model,        the cavity being configured to receive the hearing device; and    -   ensuring alignment between the receiver charging element in the        digital three-dimensional hearing device model and the        transmitter charging element in the three-dimensional charger        model to thereby maximize coupling between the receiver charging        element and the transmitter charging element.

2. A method according to item 1, wherein the method further comprisescontrolling the position of the receiver charging element in the digitalthree-dimensional hearing device model with respect to the position ofthe transmitter charging element.

3. A method according to item 2, wherein the custom digitalthree-dimensional insert model is defined by a top surface extendingthrough a plane, wherein the position of the receiver charging elementis controlled by controlling the position of the digital cavity along adirection parallel to the plane of the custom digital three-dimensionalinsert model.

4. A method according to any of the preceding items, wherein the methodfurther comprises adjusting the position of the transmitter chargingelement with respect to the receiver charging element.

5. A method according to item 4, wherein adjusting the position of thetransmitter charging element is performed by adjusting the position ofthe transmitter charging element in at least one of x or y or zdirections.

6. A method according to any of the preceding items, wherein the methodfurther comprises creating a digital three-dimensional gap in thedigital cavity of the digital three-dimensional custom insert model, thedigital three dimensional gap defining an air gap between the digitalcavity and the digital three-dimensional hearing device model.

7. A method according to any of the preceding items, wherein the hearingdevice is an inductively chargeable hearing device.

8. A method according to any of the preceding items, wherein thereceiver charging element is a receiver coil, and the transmittercharging element is a transmitter coil.

9. A method according to any of the preceding claims, wherein the custominsert is configured to have a first cavity and a second cavity forreceiving a first custom rechargeable hearing device and a second customrechargeable hearing device, respectively.

10. A method according to any of the preceding items, wherein thehearing device comprises a faceplate, the faceplate comprising thereceiver charging element.

11. A method according to any of the preceding claims, wherein thecharger comprises a lid.

12. A method according to any of the preceding items, wherein thecharger lid comprises at least one charging tower, the charging towercomprising the transmitter charging element.

13. A method according to any of the preceding items, wherein creatingthe digital cavity for receiving the hearing device in the customdigital three-dimensional insert model comprises digitally removing oneor more undercuts/negative draft in the digital cavity.

14. A kit comprising a charger and a hearing device, the chargercomprising a transmitter charging element and a custom insert beingconfigured to receive the hearing device, the hearing device comprisinga receiver charging element, the hearing device being a customrechargeable hearing device designed to be worn by a user, wherein thetransmitter charging element and the receiver charging element arealigned using the method according to any of the preceding items.

15. A system for alignment of a receiver charging element of a hearingdevice and a transmitter charging element of a charger, the hearingdevice being a custom rechargeable hearing device designed to be worn bya user, the charger comprising a custom insert, the custom insert beingconfigured to receive the hearing device the system comprising:

-   -   one or more communication interfaces configured to obtaining a        digital scan of the user's ear shape;    -   a processing unit configured to creating a digital        three-dimensional hearing device model based on the digital scan        of the user's ear shape, wherein the processing unit is        configured to add the position of the receiver charging element        to the digital three-dimensional hearing device model;        wherein the one or more communication interfaces are also        configured to providing a digital three-dimensional charger        model, wherein the processing unit is also configured to add the        position of the transmitter charging element to the digital        three-dimensional charger model;        wherein the one or more communication interfaces are also        configured to providing a generic digital three-dimensional        insert model;        wherein the processing unit is also configured to creating a        digital cavity in the generic digital three-dimensional insert        model, the digital cavity being created based on the digital        three-dimensional hearing device model to thereby obtain a        custom digital three-dimensional insert model, the cavity being        configured to receive the hearing device; and wherein the        processing unit is also configured to ensuring alignment between        the receiver charging element in the digital three-dimensional        hearing device model and the transmitter charging element in the        three-dimensional charger model to thereby maximize coupling        between the receiver charging element and the transmitter        charging element.

16. The system according to item 15, wherein the one or morecommunication interfaces comprise an interface for accessing a storagemedium, a user interface, or a combination of the foregoing.

17. A non-transitory computer-readable medium storing a set ofinstructions, an execution of which by a processing unit will cause amethod of alignment of a receiver charging element of a hearing deviceand a transmitter charging element of a charger, the hearing devicebeing a custom rechargeable hearing device designed to be worn by auser, the charger comprising a custom insert, the custom insert beingconfigured to receive the hearing device, the method comprising:

-   -   obtaining a digital scan of the user's ear shape;    -   creating a digital three-dimensional hearing device model based        on the digital scan of the user's ear shape, the position of the        receiver charging element is configured to be added to the        digital three-dimensional hearing device model;    -   providing a digital three-dimensional charger model, the        position of the transmitter charging element is configured to be        added to the digital three-dimensional charger model;    -   providing a generic digital three-dimensional insert model;    -   creating a digital cavity in the generic digital        three-dimensional insert model, the digital cavity being created        based on the digital three-dimensional hearing device model to        thereby obtain a custom digital three-dimensional insert model,        the cavity being configured to receive the hearing device; and    -   ensuring alignment between the receiver charging element in the        digital three-dimensional hearing device model and the        transmitter charging element in the three-dimensional charger        model to thereby maximize coupling between the receiver charging        element and the transmitter charging element.

LIST OF REFERENCES

-   -   2 receiver charging element    -   4 hearing device    -   6 transmitter charging element    -   8 charger    -   9 charger lid    -   10 custom insert    -   11 charging towers    -   12 cavity    -   13 flat structure of the custom insert    -   13 a top surface of the flat structure    -   13 b bottom surface of the flat structure    -   13 c peripheral rim of the flat structure    -   20 digital cavity    -   22 digital scan    -   24 digital 3D hearing device model    -   26 complete digital 3D hearing device model    -   28 generic 3D insert model    -   29 flat 3D structure of the generic 3D insert model    -   29 a top surface of the flat 3D structure    -   29 b bottom surface of the flat 3D structure    -   29 c peripheral rim of the flat 3D structure    -   30 undercut/negative draft    -   32 digital custom insert    -   100 obtaining a digital scan of the user's ear shape    -   101 importing a digital scan/creating baseline shell    -   102 creating a digital 3D hearing device model    -   103 adding the position of the receiver charging element    -   104 providing a generic digital 3D insert model    -   105 placing a digital 3D hearing device model in a generic        digital 3D insert model    -   106 placing a digital 3D charger model in a generic digital 3D        insert model    -   108 creating a digital cavity    -   109 digitally removing undercuts/negative drafts    -   112 providing a digital 3D charger model    -   114 ensuring alignment between a receiver and transmitter        charging element    -   400 hearing device design    -   401 hearing device design complete    -   402 hearing device shell manufacturing    -   403 designing a digital cavity and a digital 3D custom insert    -   404 applying transformations to create a digital cavity    -   405 defining a digital cavity location    -   406 digital cavity alignment    -   407 manufacturing a custom insert    -   408 installing a custom insert into a charger    -   409 adjusting the position of a transmitter charging element    -   410 hearing device and charger complete    -   500 hearing device design    -   501 defining the position of a receiver charging element

1. A method of configuring an insert to be made, the insert being a partof a charger, wherein the insert is for receiving a hearing devicehaving a first charging element, and is for aligning the hearing deviceand the charger, the charger having a second charging element, thehearing device being a rechargeable hearing device configured to be wornby a user, the method comprising: obtaining a digital three-dimensionalhearing device model, the digital three-dimensional hearing device modelcomprising a representation of the first charging element; obtaining adigital three-dimensional charger model, the digital three-dimensionalcharger model comprising a representation of the second chargingelement; creating a digital three-dimensional insert model to align (1)the representation of the first charging element in the digitalthree-dimensional hearing device model and (2) the representation of thesecond charging element in the three-dimensional charger model.
 2. Themethod according to claim 1, wherein a position of the representation ofthe first charging element in the digital three-dimensional hearingdevice model with respect to the representation of the second chargingelement is adjustable.
 3. The method according to claim 2, wherein theposition of the representation of the first charging element in thedigital three-dimensional hearing device model with respect to therepresentation of the second charging element is adjustable by changinga position of a digital cavity relative to a part of the digitalthree-dimensional insert model.
 4. The method according to claim 1,wherein the act of creating comprises changing a position of a digitalcavity relative to a part of the digital three-dimensional insert model.5. The method according to claim 1, further comprising changing arelative position between the representation of the second chargingelement and the representation of the first charging element.
 6. Themethod according to claim 1, further comprising changing a relativeposition between a digital cavity and a part of the digitalthree-dimensional charger model.
 7. The method according to claim 1,wherein the digital three-dimensional insert model comprises a digitalcavity, and wherein the method further comprises increasing a size ofthe digital cavity of the digital three-dimensional insert model.
 8. Themethod according to claim 1, wherein the hearing device is aninductively chargeable hearing device.
 9. The method according to claim1, wherein the first charging element is a receiver coil, and the secondcharging element is a transmitter coil.
 10. The method according toclaim 1, wherein the insert has a first cavity for receiving therechargeable hearing device, and a second cavity for receiving an otherrechargeable hearing device.
 11. The method according to claim 1,wherein the hearing device comprises a faceplate, the faceplatecomprising the first charging element.
 12. The method according to claim1, wherein the charger comprises a lid.
 13. The method according toclaim 11, wherein the charger lid comprises at least one charging tower,the charging tower comprising the second charging element.
 14. Themethod according to claim 1, wherein the act of creating the digitalthree-dimensional insert model comprises digitally removing one or moreundercuts or negative draft in a digital cavity.
 15. The methodaccording to claim 1, further obtaining a digital cavity based on thedigital three-dimensional hearing device model.
 16. The method accordingto claim 1, wherein a position of the second charging element relativeto the charger is adjustable.
 17. A kit comprising a charger and ahearing device, the charger comprising an insert configured to receivethe hearing device, the hearing device comprising a first chargingelement, the hearing device being a rechargeable hearing deviceconfigured to be worn by a user, wherein the first charging element ofthe hearing device and a second charging element at the charger arealigned using the method according to claim
 1. 18. A system forconfiguring an insert to be made, the insert being a part of a charger,wherein the insert is for receiving a hearing device having a firstcharging element, and is for aligning the hearing device and thecharger, the charger comprising a second charging element, the hearingdevice being a rechargeable hearing device configured to be worn by auser, the system comprising: one or more communication interfacesconfigured to obtaining a digital three-dimensional hearing devicemodel, the digital three-dimensional hearing device model comprising arepresentation of the first charging element; wherein the one or morecommunication interfaces are also configured to obtain a digitalthree-dimensional charger model, the digital three-dimensional chargermodel comprising a representation of the second charging element;wherein the system further comprises a processing unit configured tocreate a digital three-dimensional insert model to align (1) therepresentation of the first charging element in the digitalthree-dimensional hearing device model and (2) the representation of thesecond charging element in the three-dimensional charger model.
 19. Thesystem according to claim 18, wherein the one or more communicationinterfaces comprise an interface for accessing a storage medium, a userinterface, or a combination of the foregoing.
 20. A non-transitorycomputer-readable medium storing a set of instructions, an execution ofwhich by a processing unit will cause a method of configuring ato-be-made insert to be performed, the insert being a part of a charger,wherein the insert is for receiving a hearing device having a firstcharging element, and is for aligning the hearing device and thecharger, the charger comprising a second charging element, the hearingdevice being a rechargeable hearing device configured to be worn by auser, the method comprising: obtaining a digital three-dimensionalhearing device model, the digital three-dimensional hearing device modelcomprising a representation of the first charging element; obtaining adigital three-dimensional charger model, the digital three-dimensionalcharger model comprising a representation of the second chargingelement; creating a digital three-dimensional insert model to align (1)the representation of the first charging element in the digitalthree-dimensional hearing device model and (2) the representation of thesecond charging element in the three-dimensional charger model.